Grief Update - Engine Rebuild
Discussion
Matthew Poxon said:
I thought the same so Ged Sant kindly made me up a couple of AN-12 fittings that screw into the original rockers.
I would be interested in either a standard pair of the TVR rockers as a spare or a modified version, taller and with AN connections.
Assuming they're not silly money I'd also be interested in a set of repro TVR rocker covers, making them taller and AN fitting ready would definitely be the way to go.I would be interested in either a standard pair of the TVR rockers as a spare or a modified version, taller and with AN connections.
http://jrcast.com/?page_id=221
this guy already does custom rocker covers for a range of engines including the RV8 .. might be worth a call ?
this guy already does custom rocker covers for a range of engines including the RV8 .. might be worth a call ?
spitfire4v8 said:
http://jrcast.com/?page_id=221
this guy already does custom rocker covers for a range of engines including the RV8 .. might be worth a call ?
Good call but check that the covers have the lip to locate the rubber gaskets.this guy already does custom rocker covers for a range of engines including the RV8 .. might be worth a call ?
I had a pair made up a few years ago, great quality and cheap but the base was machined flat which makes it really difficult to make a good seal. Designed for the old cork gaske iirc.
Exhaust manifolds are back from Zircotec.
I opted for the graphite finish from their performance colours range. I was very tempted by the white but I knew it would be nightmare to keep clean.
The coating is suitable for applications up to 900 degrees Celsius. Since I am not running an airbox due to the ITBs it is important to manage the under bonnet temperatures, the Zircotec coating reduces the maniflold surface temperature by 33% and under bonnet temperatures by up to 50 degrees.
I asked Zircotec to take photos throughout the process, unfortunately none were able to be taken during the plasma coating process so but Zircotec kindly supplied a stock image.
Preparation
Any holes and areas that do not need to coated are blanked off or plugged, eg internal slip joints and flanges. To prepare the exposed areas for the coating the manifolds were subject to a two stage cleaning process. To remove any surface contamination manifolds were first cleaned using a heavy duty detergent and then sandblasted.
Bond coat
Before the ceramic coat can be applied a metallic-based bond coat is sprayed onto the surface. The bond coat ensures the outer ceramic substance properly adheres to the surface.
Ceramic coat
The ceramic coating is applied with a plasma jet onto the bond layer. A torch fires the zirconia ceramics at the surface at high speed. Like welding, an inert gas is used to stabilise the area being worked on, argon shields the are the ceramics are being fired at the surface from oxygen.
Performance Colour
The performance colour is applied after the base white ceramic coating
I opted for the graphite finish from their performance colours range. I was very tempted by the white but I knew it would be nightmare to keep clean.
The coating is suitable for applications up to 900 degrees Celsius. Since I am not running an airbox due to the ITBs it is important to manage the under bonnet temperatures, the Zircotec coating reduces the maniflold surface temperature by 33% and under bonnet temperatures by up to 50 degrees.
I asked Zircotec to take photos throughout the process, unfortunately none were able to be taken during the plasma coating process so but Zircotec kindly supplied a stock image.
Preparation
Any holes and areas that do not need to coated are blanked off or plugged, eg internal slip joints and flanges. To prepare the exposed areas for the coating the manifolds were subject to a two stage cleaning process. To remove any surface contamination manifolds were first cleaned using a heavy duty detergent and then sandblasted.
Bond coat
Before the ceramic coat can be applied a metallic-based bond coat is sprayed onto the surface. The bond coat ensures the outer ceramic substance properly adheres to the surface.
Ceramic coat
The ceramic coating is applied with a plasma jet onto the bond layer. A torch fires the zirconia ceramics at the surface at high speed. Like welding, an inert gas is used to stabilise the area being worked on, argon shields the are the ceramics are being fired at the surface from oxygen.
Performance Colour
The performance colour is applied after the base white ceramic coating
An issue that has been on the list for a while to resolve is the fact that the rocker covers do not fit over the Yella Terra roller rockers. The TVR cast rocker covers are taller than the OEM Rover versions which will clear the Yella Terra YT6000s but unfortunately they will not clear the YT6305 fully cradled system I have fitted.
The solutions I considered were:
- Modify the TVR cast rocker covers to suit
- Aftermarket rocker covers
- Valve cover spacers
The area which the rocker covers were fouling was the cut out for the original carburettor which TVR had replicated on the TVR cast versions. I had very recently paid to have the rocker covers powder coated and the ribs machined off so I was not keen on modifying to suit as this would require cutting and welding, then refinishing.
There are a variety of aftermarket options available, Dom at Power had a very nice pair in stock which we test fitted. There was also the option to have a custom pair made so for example I could opt for the text 5.3 V8 with a TVR logo.
I wanted to retain the period TVR Tuscan Challenge 4.5 Rover V8 look so I opted for the valve cover spacers.
After completing some research some owners reported reliability issues with oil leaks whereas some were fine. After some further research outside of the the TVR world I found a company in the US called Medice that produce billiet valve cover spacers for the Buick 215 (same rocker pattern as Rover V8). The Medice spacers are billet aluminium and feature a relief cut that allows the gasket material to become imbedded into the spacer providing a tighter grip of the gasket against the spacer surface.
https://medicemfg.com/
The solutions I considered were:
- Modify the TVR cast rocker covers to suit
- Aftermarket rocker covers
- Valve cover spacers
The area which the rocker covers were fouling was the cut out for the original carburettor which TVR had replicated on the TVR cast versions. I had very recently paid to have the rocker covers powder coated and the ribs machined off so I was not keen on modifying to suit as this would require cutting and welding, then refinishing.
There are a variety of aftermarket options available, Dom at Power had a very nice pair in stock which we test fitted. There was also the option to have a custom pair made so for example I could opt for the text 5.3 V8 with a TVR logo.
I wanted to retain the period TVR Tuscan Challenge 4.5 Rover V8 look so I opted for the valve cover spacers.
After completing some research some owners reported reliability issues with oil leaks whereas some were fine. After some further research outside of the the TVR world I found a company in the US called Medice that produce billiet valve cover spacers for the Buick 215 (same rocker pattern as Rover V8). The Medice spacers are billet aluminium and feature a relief cut that allows the gasket material to become imbedded into the spacer providing a tighter grip of the gasket against the spacer surface.
https://medicemfg.com/
A good decision and a nice find with those American spacers Matthew.
Before Simon sourced me a taller pair of covers I utilise the spacers that were available over here in the UK. These didn't have the recess as yours has and even though mine didn't leak I had to be super careful on assembly.
Are there any other obstacles to be overcome? When is your anticipated completion time?
To be honest, you don't need the car in this hot weather, far too hot for a TVR.....
Before Simon sourced me a taller pair of covers I utilise the spacers that were available over here in the UK. These didn't have the recess as yours has and even though mine didn't leak I had to be super careful on assembly.
Are there any other obstacles to be overcome? When is your anticipated completion time?
To be honest, you don't need the car in this hot weather, far too hot for a TVR.....
The engine and car are with Jody for installation. Before the engine is installed we decided to take the opportunity to tidy up the engine bay. The car had a new chassis from RT racing fitted 2009, the chassis has been regularly inspected every since and Wazoyl applied at the annual service. The removal of the old engine revealed areas where paint had flaked off and areas of light surface rust.
The heat shields were removed and and given to a local company to fabricate new ones using the old ones as templates. The result is fantastic and a higher quality finish compared to the originals, especially the stitching.
Regarding the chassis I didn't want to fall into the trap of repainting the whole chassis with the body in situ, not being happy with the finish and end taking the body off and delaying the project further. After speaking to Jody we agreed that repainting just the top rails would be a suitable compromise as the immediately viable part of the chassis around the new engine will be freshened up from an aesthetic point of view and the area where the engine sits is protected.
The top rails now have 3 coats of POR15 and the engine is ready to be installed once the heat shields are refitted.
The heat shields were removed and and given to a local company to fabricate new ones using the old ones as templates. The result is fantastic and a higher quality finish compared to the originals, especially the stitching.
Regarding the chassis I didn't want to fall into the trap of repainting the whole chassis with the body in situ, not being happy with the finish and end taking the body off and delaying the project further. After speaking to Jody we agreed that repainting just the top rails would be a suitable compromise as the immediately viable part of the chassis around the new engine will be freshened up from an aesthetic point of view and the area where the engine sits is protected.
The top rails now have 3 coats of POR15 and the engine is ready to be installed once the heat shields are refitted.
phazed said:
A good decision and a nice find with those American spacers Matthew.
Before Simon sourced me a taller pair of covers I utilise the spacers that were available over here in the UK. These didn't have the recess as yours has and even though mine didn't leak I had to be super careful on assembly.
Are there any other obstacles to be overcome? When is your anticipated completion time?
To be honest, you don't need the car in this hot weather, far too hot for a TVR.....
Hi Peter,Before Simon sourced me a taller pair of covers I utilise the spacers that were available over here in the UK. These didn't have the recess as yours has and even though mine didn't leak I had to be super careful on assembly.
Are there any other obstacles to be overcome? When is your anticipated completion time?
To be honest, you don't need the car in this hot weather, far too hot for a TVR.....
Plenty more obstacles to overcome unfortunately as it the nature of doing something a bit different, which I am sure you are all too aware of from your epic 5.5.
I will lose the ability to vent the rockers to the plenum as per the OEM design so a suitable oil catch tank will need purchasing and locating.
Vacuum for the brakes will also be lost with the plenum so I am hoping a single ITB will be sufficient otherwise I will require a vacuum block fed from multiple ITBs
Electronic water pump needs to be installed.
Swirl tank will need to modified to suit the new location of the thermostat housing
Space is going to be an issue with the Clive F equal length headers.
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